Metso MP800 Technical Reference Manual
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Metso MP800 Technical Reference Manual

Cone crusher
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  • Page 1 Nordberg MP Series Cone Crusher...
  • Page 3 The description and specifications in this manual were in effect at the time this manual was approved for printing. Metso Minerals reserves the right to discontinue models at any time and to change specifications or design, without notice and without incurring obligation.
  • Page 5 Table of Contents Safety ............. Section 0 General Crusher Information.

  • Page 7: Table Of Contents

    Section 0 Safety Introduction ............. . 0.1.1 General .

  • Page 9: Introduction

    0.1.1 General This manual, together with specific instruction manuals for individual equipment, has been prepared by Metso Minerals to increase the knowledge and awareness of all persons involved in the operation, supervision, service and maintenance of crushing and screening equipment with regard to safety and operations.

  • Page 10: Definitions

    No changes shall be made in the operation of the machinery supplied by Metso Minerals or the contents of this manual without express written approval of Metso Minerals. All operation, service,...

  • Page 11: General Safety Instructions For A Crushing Plant Or Plant Environment

    NOTICE accidents and injuries. Metso Minerals, as machinery manufacturer and supplier, is committed • If unsure of any procedure, check the...
  • Page 12 SECTION 0 - SAFETY 0.2.2.2 Safety Signs, Labels And Symbols The following symbol is used in this manual and on DANGER the machine to call attention to instructions which will help prevent machine related injuries. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
  • Page 13 SECTION 0 - SAFETY 0.2.2.3 Some General Safety Instructions tested and certified for appropriate operation by skilled personnel. 1. Do not remove, cover or disable any installed safety devices, guards, warning 9. Personal protective equipment and safety signs or tags. They are attached to uniforms, safety shoes, helmets, safety equipment to warn personnel of possible glasses, heavy gloves, ear protection devices...
  • Page 14 SECTION 0 - SAFETY 0.2.2.7 Blasting WARNING Only qualified properly trained operators and servicemen should operate or service the machine. Everyone else should stay clear of the machine when it is operating, or under service or maintenance! 0.2.2.4 Safety Instructions after Start-up 1.

  • Page 15: Typical Risks In Crushing Plant Working Environment

    Follow all disassembly and assembly instructions carefully. Disconnect all external power supplies before Even though every Metso Minerals machine is moving any part of the equipment. Transport or designed with many safety features, it is impossible hoist components and handle any parts in to design out all safety risks.
  • Page 16 SECTION 0 - SAFETY – automatic functions and unexpected An ingoing nip is formed by drive devices such as start-ups belt and pulley, chain and sprocket or gears. Similarly, a pinch point may be formed by rotating – toxic and corroding agents or moving equipment.
  • Page 17 SECTION 0 - SAFETY Elevated or Narrow Working Location Do not use chain hoists (chain blocks) to assemble or disassemble a Crushing Plant. These lifting devices lack the stability and robustness required in lifting and positioning heavy components. Do not use impact hammer boom or any other equipment which are not designed for lifting, for assembly or disassembly purposes.
  • Page 18 SECTION 0 - SAFETY Sharp Edges NOTICE When using a mobile crane, always operate within the rated capacity of the machine to avoid buckling the boom or tipping. Take the following precautions when lifting heavy loads: – Follow all established Crushing Plant procedures.
  • Page 19 SECTION 0 - SAFETY Regularly check the condition of hoses, pipes, Protect electrical devices that move as part of the valves and various connections. Replace them as machine from dirt and mechanical damage. necessary. Regularly check the operability of these devices. Before starting any maintenance work, stop all hydraulic pumps, lock out pump motors, and DANGER...
  • Page 20 SECTION 0 - SAFETY Automatic Functions and Unexpected Start-Ups DANGER If danger zones are not respected during machine operation or maneuvers there is a risk of serious injury or death. Many devices operate automatically, following certain sequences which have been programmed into the logic system (e.g., programmable logic...
  • Page 21 Regularly inspect the structural elements to CAUTION maintain safe operation. Contact Metso Minerals or its authorized Hot Surfaces and Fires representative prior to any welding of major Crushing Plant components such as main...
  • Page 22 SECTION 0 - SAFETY and other combustible material in a safe place. – Never use an open flame to check fuel, battery electrolyte or coolant levels, or to look for hydraulic leaks anywhere on the equipment. Use a flashlight. Know where fire extinguishers are kept, how they operate, and for what type of fire.
  • Page 23 Owner and Operator consult Never attempt to stand on, walk on, or step Metso Minerals or a dust consultant about possible across a conveyor. Never stand below a alternative means of dust reduction.
  • Page 24 Crushing Plant itself. Typical Crushing Plant noise level while crushing ranges from 100 dB to 110 dB measured at 1 m (3 ft) from the Crushing Plant. Metso Minerals recommends wearing ear protection at, on and around Crushing Plant, Improper work methods and motions may cause particularly when the noise level exceeds 85 dB.
  • Page 25 RPM readings are being WARNING taken. Never change sheave combinations without first consulting your Metso Minerals representative. Do not use sheaves with damaged rims or spokes. Ejection of Objects from the Crushing Plant OUTRIGGER CONTACT MAY CAUSE...
  • Page 26 SECTION 0 - SAFETY To help avoid injury, be aware of parts positioned Cutting close to the floor level or protruding machine components, changes in elevation of platforms, walkways, and narrow access points. It is recommended that safety shoes be worn at all times.

  • Page 27: Personal Protective Equipment And Clothing

    SECTION 0 - SAFETY Burns and Electrical Shocks Do not stand in front of the feed opening or look into the crushing cavity while the crusher is operating. 0.2.4 Personal Protective Equipment and Clothing Personal protective equipment and clothing such as foot protection, helmet, hearing protection, dust protective devices, safety glasses or other personal protective clothing and equipment should be worn...
  • Page 28 NOTICE design, or wear eye protection that can be worn over the prescription lenses without Metso Minerals highly recommends that disturbing the proper position of the adequate dust-protective devices such as a prescription lenses or the protective respirator be worn by anyone exposed to lenses.
  • Page 29 SECTION 0 - SAFETY 0.2.4.5 Head Protection equipment, including safety harnesses, if there is a risk of falling. Confined spaces may also require safety harnesses. 0.2.4.8 Work Clothing The Owner should ensure that affected personnel wear a protective helmet approved by OSHA, MSHA (or by other applicable authority) when working in areas where there is a potential for head injuries from falling objects or walking throughout...

  • Page 30: Machine Safety

    Follow all lock-out tag procedures. Refer to safety features are restored. appropriate standards and instructions provided by Metso Minerals. 0.3.1.2 Emergency-Stop (E-Stop) DANGER For maintenance work, disconnect all devices from electric power sources.
  • Page 31 A machine already in operation may need to stop quickly due to Operator accumulators. Metso Minerals uses these error, safety violations, or an unexpected machine components where applicable in the hydraulic event.
  • Page 32 SECTION 0 - SAFETY Safety Gates machine or a machine function. The warning device for start-up should operate so that personnel are given sufficient time to move to a safe distance from the machine. It is the responsibility of the Owner to ensure that the Crushing Plant is always equipped with required horns and lights.

  • Page 33: Transport

    SECTION 0 - SAFETY – Check if towing is allowed for each CAUTION individual equipment. 0.3.4 At the work-site Extreme caution must always be used on machine walkways. 0.3.4.1 Precautions Observe the following minimum precautions at the 0.3.2 Transport work-site: Observe the following precautions before 1.

  • Page 34: Safety During Maintenance And Repair

    SECTION 0 - SAFETY completely, lock and tag out all applicable controls – Know the whereabouts of all personnel in, and follow all instructions in the instruction manual on, at and around the machine. of your specific crusher. – Never service any machine or component without first referencing its maintenance 0.4 SAFETY DURING MAINTENANCE AND manual.

  • Page 35: Mechanical Safety During Maintenance And Repair

    SECTION 0 - SAFETY 0.4.2 Mechanical Safety During NOTICE Maintenance and Repair Be sure all mechanical components are brought to a zero energy state including all spring driven devices, cylinders, accumulators, drive shafts, pulleys, rollers, gears, etc., prior to entering the machine and performing the work.
  • Page 36 SECTION 0 - SAFETY 0.4.2.2 Fire Safety During Maintenance and in the middle of a production cycle. A machine or Repair device that is not in proper condition, and that has been left without regular maintenance and inspections, is a safety risk to its user. For instance, without lubrication a bearing may fail, bringing a production line down.

  • Page 37: Electrical Safety During Maintenance And Repair

    SECTION 0 - SAFETY Be sure all electrical components are brought to a DANGER zero energy state including capacitors and similar electrical devices. Confined spaces contain high Before maintenance work: concentrations of gases which may cause – Be sure all control power supplies are injury or death.

  • Page 38: Hydraulic Safety During Maintenance And Repair

    Work to eliminate injury and death. Changes to Metso Minerals’ supplied control Follow proper procedures at all times! program should be made only by Metso Minerals personnel. Faulty program code Before proceeding with any repair, maintenance or cause...

  • Page 39: General Maintenance Work

    SECTION 0 - SAFETY – Purge entrapped air from the hydraulic – Avoid letting dirt and other impurities into system. Entrapped air in the hydraulic the system while doing maintenance work. system can cause erratic and unexpected Use lint free cloths for cleaning the movements.
  • Page 40 – Do check the manufacturer's recommendations for periodic – Use only quality Metso replacement parts. maintenance procedures. These Handle parts carefully to prevent damage maintenance procedures are designed to to machined surfaces. Machined surfaces not only avoid damage to the equipment may have sharp edges.

  • Page 41: Safety Plates

    SECTION 0 - SAFETY 0.5 SAFETY PLATES 0.5.1 Safety Plates — ANSI WARNING DANGER Material can Moving parts can crush and cut. fall out. Do not stand in the Do not stand in the vicinity of the vicinity of the crusher when the crusher when the engine is running.
  • Page 42 SECTION 0 - SAFETY WARNING DANGER Fall hazard. Moving parts can crush and cut. Do not stand on Lock the rotor with the machine. a locking pin before entering the crusher. WARNING DANGER Moving parts can Dropping crush and cut. material.
  • Page 43 SECTION 0 - SAFETY WARNING CAUTION Powerful Powerful magnet. magnet. People using Stay away from the pacemakers must magnet. not go near the magnet. CAUTION DANGER Hot surface. Moving parts can crush and cut. Contact with skin Do not go near the may cause burns.
  • Page 44 SECTION 0 - SAFETY DANGER WARNING Material can Exposed moving fall out. parts can cause severe injury. Watch out for Do not open cover material dropping when engine is from the bucket. running. DANGER DANGER Exposed moving Exposed moving parts can cause parts can cause severe injury.
  • Page 45 SECTION 0 - SAFETY WARNING DANGER Servicing while Explosion pressurized can Hazard. cause severe injury. Switch off the Lock out source and radio control relieve pressure before blasting. before servicing. DANGER CAUTION Lung disease Risk of head hazard. injury. Dust protection Use of helmet required.
  • Page 46 SECTION 0 - SAFETY WARNING Risk of eye injury. Use of eye protection required. CAUTION Hazardous noise level. Use of ear protection required. 0-38 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 47 SECTION 0 - SAFETY WARNING Read and understand operating manual before using this machine. Failure to follow operating instructions may result in death or serious injury. WARNING Exposed moving parts can cause severe injury. Do not stop under the conveyor. WARNING Dropping material.
  • Page 48 SECTION 0 - SAFETY CAUTION FALLING MATERIAL WEAR HARDHAT WHEN USING THIS EQUIPMENT. CAUTION WEAR SAFETY GLASSES WITH SIDESHIELDS WHEN USING THIS EQUIPMENT. WARNING EXPOSED MOVING PARTS CAN CAUSE SEVERE INJURY. DO NOT OPERATE WITHOUT GUARD IN PLACE. LOCKOUT POWER BEFORE STARTING.
  • Page 49 SECTION 0 - SAFETY WARNING OUTRIGGER CONTACT MAY CAUSE SERIOUS CRUSHING INJURY STAND CLEAR CAUTION REMOVE SHIPPING BRACE BEFORE OPERATING PLANT CAUTION REPLACE SHIPPING BRACE BEFORE MOVING PLANT 0-41 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 50 SECTION 0 - SAFETY CAUTION CRIB MACHINE BEFORE OPERATION TO PREVENT FATIGUE DAMAGE CAUTION HIGHWAY SPEED NOT TO EXCEED 40 MPH PIT SPEED NOT TO EXCEED 5 MPH DANGER EXPOSED MOVING PARTS CAN CAUSE SEVERE INJURY. DO NOT OPERATE WITHOUT GUARD IN PLACE.

  • Page 51: Safety Plates - En

    SECTION 0 - SAFETY 0.5.2 Safety Plates — EN Do not stand in the vicinity of the crusher when the Do not stand in the vicinity of the crusher when the engine is running. engine is running. Do not stand on the machine. There are moving parts behind the protecting cover.
  • Page 52 SECTION 0 - SAFETY Do not go near the feeder when the engine is Do not go under the machine when the engine is running. running. Mind the hot surface. Mind the high-pressure liquid. 0-44 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 53 SECTION 0 - SAFETY Stay away from the powerful magnet. Read the user instructions. Do not open the hatch when the rotor is moving. Lock the rotor before entering the crusher. 0-45 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 54 SECTION 0 - SAFETY Watch out for material dropping from the conveyor. Watch out for material dropping from the bucket. Rotation direction of the vibrator. Switch off the radio control before blasting. 0-46 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 55 SECTION 0 - SAFETY Emergency stop. Conveyor emergency stop. Conveyor emergency stop wire. Do not open the main current switch when the engine is running. 0-47 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 56 SECTION 0 - SAFETY Close the hatch before lowering the conveyor. Stay away from the crusher cavity. Do not step under the conveyor. Use a safety rod to prevent the crusher from closing. 0-48 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 57 SECTION 0 - SAFETY Do not insert tools in the crusher cavity when the Pressure accumulator. engine is running. Do not open the hatch when the engine is running. 0-49 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 58 SECTION 0 - SAFETY Do not attach or detach hydraulic connection when Keep the door closed when the engine is running. the engine is running. Tighten the wheel nuts to the specified torque when Use the pin to lock the conveyor before moving the changing tires.
  • Page 59 SECTION 0 - SAFETY Use the pin to lock the conveyor before starting the Oil. crushing. Oil recommendation. Use of respirators required. 0-51 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 60 SECTION 0 - SAFETY Inspect every 8 hours and tighten every 40 hours. Lock the catch. Use of hearing protectors required. Use of helmet required. 0-52 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 61 SECTION 0 - SAFETY Greasing point. Check every 8 hours. Fuel tank. Use of eye shields required. 0-53 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 62 SECTION 0 - SAFETY Engine oil. Valve. Hydraulic oil. Oil recommendation. Coolant. 0-54 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 63 SECTION 0 - SAFETY DANGER! Electric shock. CE mark. Fastening flat bar. Conveyor safety switch. People using pacemakers must not go near the magnet. 0-55 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 64 SECTION 0 - SAFETY 0-56 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 65 Section 1 General Crusher Information Introduction ............. . Initial Inspection .
  • Page 67 Crusher 1.4 Repair Parts and as an aid in gaining the general knowledge Metso Minerals endeavors to carry an ample supply necessary for efficient operation and maintenance. of parts in stock to provide prompt and efficient When operating the Crusher certain safeguards service on all orders for repairs and replacements.
  • Page 68 SECTION 1 - GENERAL CRUSHER INFORMATION Feed Opening (Closed Side) — The smallest is important and the product is screened after distance between the top of the crushing members passing through the Crusher and the material which as measured when the two crushing members are at does not pass through the screen is returned to the their closest relationship during their gyrating Crusher.
  • Page 69 If for any reason, it is felt that unsatisfactory wear crushing cavity unsuited to the operation, results in life was obtained from the original liners, Metso uneconomical wear of the liners, poor crushing Minerals suggests that the bowl liner and mantle be...
  • Page 70 SECTION 1 - GENERAL CRUSHER INFORMATION Standard Short Head Callouts 1 Feed plate 9 Bowl liner 17 Countershaft 26 Gear Lower head bushing 2 Head ball 27 Eccentric Tramp release Countershaft box cylinder guard 3 Hopper 28 Arm guard 34 Bowl 11 Socket liner 19 Oil flinger 35 Feed cone...
  • Page 71 SECTION 1 - GENERAL CRUSHER INFORMATION Standard Short Head Callouts 1 Feed plate 17 Couterweight 25 Pinion Adjustment T-and U-seal Ring (Upper) 18 Sheave Head Stub Upper and Lower Bolt Thrust Bearing 9 Head Counterweight Outer Guard 3 Head Ball 10 Bowl Liner Countershaft 27 Eccentric...
  • Page 72 SECTION 1 - GENERAL CRUSHER INFORMATION This Page Left Intentionally Blank. MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 73 Section 2 General Installation Information Foundation ............. . Crusher Clearance Dimensions .
  • Page 75 Crusher. NOTICE Foundation must be acceptable for loadings. Obtain technical data sheets with foundation loads from Metso Minerals. It is customer’s responsibility proper design construction. 2.2 Crusher Clearance Dimensions A well planned installation is an absolute necessity for the ultimate success of the Crusher.
  • Page 76 SECTION 2 - GENERAL INSTALLATION INFORMATION Figure 2-1 Typical MP800 Mounting and Clearance Drawing MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 77 SECTION 2 - GENERAL INSTALLATION INFORMATION Figure 2-2 Typical MP1000 Mounting and Clearance Drawing MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 78 SECTION 2 - GENERAL INSTALLATION INFORMATION Bowl Assembly Head Assembly Figure 2-3 MP800 Clearance Dimensions MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 79 SECTION 2 - GENERAL INSTALLATION INFORMATION Table 2-1 MP800 Clearance Dimensions (refer to Figure 2-3) Standard Short Head Callout Description mm (in.) mm (in.) 1750 1750 Main frame flange (5' 8-7/8") (5' 8-7/8") 1750 1750 Main frame flange (5' 8-7/8") (5' 8-7/8") 1750 1750...
  • Page 80 SECTION 2 - GENERAL INSTALLATION INFORMATION Table 2-2 MP800 Crusher and Sub-Assembly Weights Weights Assemblies kg (lbs) 120,570 Crusher complete (265,850) Main frame, adjustment ring, clamp ring, clamping cylinders, tramp release, eccentric, 72,450 socket, countershaft box, countershaft and crusher sheave (159,750) 61,855 Main frame, adjustment ring, clamp ring, clamping cylinders, and tramp release...
  • Page 81 SECTION 2 - GENERAL INSTALLATION INFORMATION Bowl Assembly Head Assembly Figure 2-4 MP1000 Clearance Dimensions MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 82 SECTION 2 - GENERAL INSTALLATION INFORMATION Table 2-3 MP1000 Clearance Dimensions (refer to Figure 2-4) Standard Short Head Callout Description mm (in.) mm (in.) 1950 1950 Main frame flange (6' 4-3/4") (6' 4-3/4") 2000 2000 Main frame flange (6' 6-3/4") (6' 6-3/4") 1950 1950...
  • Page 83 SECTION 2 - GENERAL INSTALLATION INFORMATION Table 2-4 MP1000 Crusher and Sub-Assembly Weights Weights Assemblies kg (lbs) 150,494 Crusher complete (331,782) Main frame, adjustment ring, clamp ring, clamping cylinders, tramp release, eccentric, 94,231 socket, countershaft box, countershaft and crusher sheave (207,744) 80,929 Main frame, adjustment ring, clamp ring, clamping cylinders, and tramp release...
  • Page 84 SECTION 2 - GENERAL INSTALLATION INFORMATION 2.4 Feed Arrangement the feed arrangement that should include a rock box. The feed material should overshoot the center The feed material going to the Crusher must be of the Crusher and impact into a dead bed rock box controlled to keep the Crusher from overflowing, to which has a feed chute that can be located so that keep the Crusher from drawing too much power...
  • Page 85 SECTION 2 - GENERAL INSTALLATION INFORMATION Lesser feed arrangements will have a direct effect The correct and incorrect methods of feed and feed on the performance of the Crusher. If the feed rate box construction are shown in Figure 2-5. Also control point is farther from the Crusher or if a refer to the suggested feed arrangement drawing, scalping screen is located between the feed rate...
  • Page 86 SECTION 2 - GENERAL INSTALLATION INFORMATION Figure 2-6 Suggested Circuit Diagram for Optimum Crusher Productivity 2.5 Discharge Arrangement up under the head and interfere with the operation of the Crusher. This will ensure a free unimpeded Since the discharge arrangement varies with each discharge of crushed material.
  • Page 87 The motor manufacturer Banded belts are single belts unitized with a should contact Metso Minerals regarding the gear common cover to prevent belt whip or turnover. mesh frequency for motor design. The motor will...
  • Page 88 SECTION 2 - GENERAL INSTALLATION INFORMATION 2.8.2 Tensioning the V-belt Drive Various methods of tensioning V-belts have been established. Two simplified methods will be Tensioning the drive is a term used when force is described in the following paragraphs; Tension- applied to the V-belt by some method to provide the Deflection and Percent (%) of Elongation.
  • Page 89 SECTION 2 - GENERAL INSTALLATION INFORMATION Minimum Allowance mm (inches) Below Center Distance For Installation of Belts V-belt Section Minimum Allowance Above Center Distance Belt Length* mm (inches) For Stretch and Wear Power Band All Sections 630 (25) thru 1199 (47) —...
  • Page 90 SECTION 2 - GENERAL INSTALLATION INFORMATION 3. Measure the span length. 4. Using a tension device or spring scale at right angles to the center of the span length, apply a force to the device or scale great enough to deflect one of the belts the equivalent of 0.016 times millimeters of span length (0.016 times inches of span length).
  • Page 91 13.6 (30) 17.7 (39) 17.7 (39) Gates Other Consult Metso Minerals Brands Note: These forces are for individual belts and must be multiplied by the number of belts per band if banded belts are being used. Table 2-6 Deflection Forces...
  • Page 92 SECTION 2 - GENERAL INSTALLATION INFORMATION SEE THE APPROPRIATE FOLLOWING 3. After the 2 hour period, retension so that the SECTION FOR THE CORRESPONDING force is between the MINIMUM and CONDITIONS REGARDING NEW OR MAXIMUM TENSION shown in Table 2-6. EXISTING BELTS AND NEW OR EXISTING 4.
  • Page 93 Multiplier MP800 0.005 0.006 Standard Optibelt MP1000 0.006 0.007 MP800 0.006 0.007 Banded Optibelt MP1000 0.007 0.008 Gates Tension Deflection Method Recommended Other Consult Metso Minerals Brand Belts Table 2-7 Elongation Factors 2-19 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 94 SECTION 2 - GENERAL INSTALLATION INFORMATION 2.8.9 Percent Elongation Method 2. Run the Crusher WITHOUT material for a period of 2 hours. See INITIAL START-UP AND General method for tensioning V-belt drives. BREAK-IN PROCEDURE in Section 11. 1. With the V-belts or bands on the drive at NO 3.
  • Page 95 SECTION 2 - GENERAL INSTALLATION INFORMATION 2.9 V-belt Precautions bearing problems resulting from over tensioning. Reduce belt tension if Some of the do’s and don’ts in connection with countershaft box exterior temperature proper V-belt drive operation are as follows: increases and exceeds oil drain line 1.
  • Page 96 SECTION 2 - GENERAL INSTALLATION INFORMATION Callout Description Callout Description Countershaft Tight (no gap) Inner countershaft bushing No clearance (tight) Outer countershaft bushing Measure end float here Oil flinger • 1.5 mm (0.060") to Sheave bushing • 0.8 mm (0.030") Sheave key Set collar (for direct drive or shipping) Clamp screw...
  • Page 97 SECTION 2 - GENERAL INSTALLATION INFORMATION 5. Loosen the clamp screw and slide the bushing onto the countershaft aligning the sheave key and keyway. If necessary, insert a wedge (example: screwdriver) into bushing slit to aid in installation of bushing. Tighten clamp screw when bushing is tight against oil flinger.
  • Page 98 SECTION 2 - GENERAL INSTALLATION INFORMATION 2.12 Crusher Sheave Removal NOTICE To remove the crusher sheave, refer to Figure 2-13 and proceed as follows: Should there be difficulty “breaking” the fit 1. Remove the take-up capscrews and thread between the sheave and bushing, tap the two of them into the tapped holes in the hub end of the shaft or bushing with a babbitt of the sheave.
  • Page 99 SECTION 2 - GENERAL INSTALLATION INFORMATION 2.13 Jack Shaft Drive a special crusher drive motor that is very expensive. To minimize motor cost, we recommend a jack Due to the large belt pull the motor shaft and shaft drive design (refer to Figure 2-14) for use in bearings must handle, a system with the motor conjunction with our recommended V-belt drive.
  • Page 100 SECTION 2 - GENERAL INSTALLATION INFORMATION 2. Inspect both the driving and driven shafts NOTICE and coupling bores, making sure they are free from burrs, scratches, and all foreign matter. Be sure the keys fit the shafts and Do not heat the coupling hub over 135°C coupling halves properly.
  • Page 101 SECTION 2 - GENERAL INSTALLATION INFORMATION Callout Description Callout Description Pinion Flexible Coupling Inner Countershaft Bushing Safety Set Collar Outer Countershaft Bushing Tight Oil Flinger Figure 2-15 End Float - Direct Drive Initial Alignment Of Flexible Coupling 2. Check parallel alignment by laying a straight edge across the outside diameter of For the initial installation or when reassembling the the coupling halves, at four places, 90°...
  • Page 102 SECTION 2 - GENERAL INSTALLATION INFORMATION 1. Equal Gap 1. Hold Straight Edge Tight Against Coupling 2. Check with Feeler Gauge for Proper Gap and Angular Half at This Point Alignment on Other Coupling Half at This Point — Check 2.
  • Page 103 Crusher is designed Clamping Ring threads which should be treated for 8.6 BAR (200 PSI) maximum operating with a special thread lubricant (supplied by Metso pressure. Minerals) before applying the special grease with Consult piping drawings furnished to show the pipe...
  • Page 104 Whenever possible, heating should be consists of several Crushers, this list should be performed with an immersion oil bath or a expanded. Therefore, consult Metso Minerals for a temperature controlled oven. suggested list of spare parts for your particular –...
  • Page 105 Crusher. The backlash measuring tool for the MP800 or the MP1000 is available from your local Metso Minerals representative. 2-31 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 106 SECTION 2 - GENERAL INSTALLATION INFORMATION VARIOUS SIZES OF METRIC FLAT WASHERS LINE-UP STUD USED TO ASSEMBLE SOCKET TO MAINSHAFT MAINSHAFT SUPPORT LOCKING NUT WRENCH ACCUMULATOR CHARGING ASSEMBLY 60° FOR PROPER LIFTING SEE NOTES BELOW. Notes for Correct Lifting: 1. Lifting ring bolts must always be screwed tight in such a way that they fit flush against the bearing surface.
  • Page 107 SECTION 2 - GENERAL INSTALLATION INFORMATION Description (See Tools Assembly in customer-specific parts book for Metso replacement part numbers.) Item Number Head assembly with mantle and X X X locking nut (without feed plate) Head assembly with locking nut X X X...
  • Page 108 SECTION 2 - GENERAL INSTALLATION INFORMATION VARIOUS SIZES OF METRIC FLAT WASHERS LINE-UP STUD USED TO ASSEMBLE SOCKET TO MAINSHAFT MAINSHAFT SUPPORT ACCUMULATOR LOCKING NUT CHARGING WRENCH ASSEMBLY 60° FOR PROPER LIFTING SEE NOTES BELOW. Notes for Correct Lifting: 1. Lifting ring bolts must always be screwed tight in such a way that they fit flush against the bearing surface.
  • Page 109 SECTION 2 - GENERAL INSTALLATION INFORMATION Description Item Number Head assembly with locking nut (with X X X or without mantle, without feed plate) Upper Head Bushing Lower Head Bushing Head Ball Locking Nut Socket Liner Socket Main Shaft Main Frame Pin Main Frame Pin Bushing Lower Thrust Bearing Upper Thrust Bearing...
  • Page 110 SECTION 2 - GENERAL INSTALLATION INFORMATION Tool Measure Motion Number Perpendicular Here to this Surface Figure 2-19 Backlash Measuring Tool 2-36 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 111 Metso Minerals suggests the use of all areas of the head adjacent to the T-seal. Mobilarma 522 or equivalent. The rust 7. Reinstall the eccentric assembly and the preventives function by displacing water socket assembly.
  • Page 112 The additive should have excellent ability to wet metal surfaces in the presence of water; The following is Metso Minerals recommendations as a result it strongly resists displacement for preparation for storage (up to one year) of a from the surface by water.
  • Page 113 SECTION 2 - GENERAL INSTALLATION INFORMATION Use the following procedures to prepare holes of the main shaft. If the main frame is components and subassemblies for extended to be left outdoors exposed to the elements, storage whether the Crusher is fully assembled or it is recommended that the main shaft be received as subassemblies.
  • Page 114 SECTION 2 - GENERAL INSTALLATION INFORMATION indoors. Remove all clamping cylinders accumulator facing up. Store the crate from the clamp ring and fill each cylinder indoors. with Mobilarma 522 or equivalent. Drain 5. Eccentric Assembly — Remove the each cylinder and plug port with a metal counterweight and gear from the eccentric SAE O-ring plug.
  • Page 115 SECTION 2 - GENERAL INSTALLATION INFORMATION 522 or equivalent, the oil will eventually other top 3 inch line with an SAE 150# blind flow through the pump and into the suction flange and gasket with 1" female NPT line, then into the reservoir. When the oil threads in the center of the blind flange.
  • Page 116 2.22 Long Term Storage of a Crusher The following is Metso Minerals recommendations for LONG TERM STORAGE (up to two years) of a crusher When storing a Crusher for a period of no more...
  • Page 117 Section 3 Main Frame, Adjustment Ring, Tramp Release & Clearing Jack Assemblies Description ............. . Assembly Instructions .
  • Page 118 Callout Description Callout Description Clamping ring Main frame Adjustment ring U-seal Main shaft Lower thrust bearing Mainframe liner Main frame pin Main Frame, Adjustment Ring, Tramp Release and Clearing Jack Assemblies...

  • Page 119: Description

    Once the overload has passed and Contact Metso Minerals for structural and crushing forces normalize, the compressed nitrogen machining requirements. will return the oil to the cylinder, the cylinder rods...

  • Page 120: Oil Temperature Rtds

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY crusher anchor bolts and onto the steel structure. 3. Attach a suitable sling or slings to the lifting bosses at the bottom of the main frame flange. WARNING Do not use the lifting lugs on the adjustment cap for lifting the entire machine.

  • Page 121: Maintenance

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY Callout Description Callout Description Main shaft Main frame Lower thrust bearing RTD cable RTD Sensor Drain line Figure 3-1 Eccentric Bushing RTD Installation 3.3 Maintenance On the MP800 it will be necessary to remove the counterweight guard and stationary guard (if used) 3.3.1 Main Frame Liner and Arm Guards in order to remove or install the arm guard.

  • Page 122: Main Shaft Replacement

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY MP800 MP1000 Callout Description Main frame Main frame liner Arm guard Stationary guard Counterweight guard Figure 3-2 Main Frame Liner and Arm Guard 3.3.2 Main Shaft Replacement 3.3.3 Lower Thrust Bearing and Shim Replacement The need to replace a main shaft should be...
  • Page 123 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3. Thread a ring bolt into each of the two 6. Refer to Adjusting Gear Backlash for Wear tapped holes in the thrust bearing. in Section 5, to determine the correct amount of shims to be installed.

  • Page 124: Seal Replacement

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3.3.4 Seal Replacement The U-shaped seal installed around the gear well portion of the main frame is normally not subjected to contact or wear. However, if the seal is damaged in any way, it is important that it be replaced.

  • Page 125: Main Frame Pins And Pin Bushings

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3.3.5 Main Frame Pins and Pin Bushings WARNING The main frame pins prevent the adjustment ring from rotating in respect to the main frame and also Prior to performing maintenance work on guide the adjustment ring back to its original any part of the Crusher, lockout and tag all position when the ring lifts due to tramp iron or...
  • Page 126 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 5. To install a new pin bushing, pack the bore If the pin can not be removed by this method of the replacement bushings with dry ice for then cut out the center of the pin with a two to three hours to shrink the bushings for lance, then retry step 3.

  • Page 127: Main Frame Seat Liner And Fulcrum Bar

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY MP1000 MP800 Callout Description Callout Description Pin cover Main frame pin Adjustment ring Pin retainer Main frame pin bushing Main frame Figure 3-6 Main Frame Pins and Pin Bushings 3.4 Main Frame Seat Liner and Fulcrum Bar 3.4.1 General Information Periodically, the main frame seat liner and fulcrum...
  • Page 128 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY Callout Description Install Shackles and attach lifting slings (four places) Figure 3-7 Lifting Adjustment Ring MP1000 MP800 Callout Description Adjustment ring Main frame fulcrum bar Bronze main frame seat liner Main frame Figure 3-8 Main Frame Seat Liner and Fulcrum Bar 3-10...

  • Page 129: Main Frame Seat Liner Wear

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3.4.2 Main Frame Seat Liner Wear To determine exactly how much wear is taking place on the main frame, proceed as follows: MP1000 1. Starting at the countershaft box and in line with a clearing jack, identify on the outside surface of the adjustment ring four spots 90°...
  • Page 130 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY MP800 all the way around the Crusher. Due to casting and machining variations this is the 1. Starting at any release cylinder, identify, on only accurate method in which wear can be the outside surface of the adjustment ring determined.
  • Page 131 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY Callout Description Callout Description Main frame fulcrum bar Measure wear here Adjustment ring Release cylinder 2 mm (0.080") to 5 mm (0.196") gap required after new main frame fulcrum Main frame bars and seat liner are installed Figure 3-10 Determining Seating Surface Wear (MP800)

  • Page 132: Main Frame Seat And Fulcrum Bar Installation

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3.4.3 Main Frame Seat and Fulcrum Bar Installation There is a gap between the main frame fulcrum bar 10 mm (.39") and adjustment ring fulcrum surface that is to be maintained when seat liners and fulcrum bars are replaced.
  • Page 133 20°C (68°F) to 40°C least the maximum clearance. If weld (105°F). build up is required, then contact Metso Minerals for weld and machining 5. Weld the fulcrum bar as shown. procedures.
  • Page 134 If weld build up is required, then contact Metso Minerals for weld and machining procedures. 22 mm 100-260 mm 6 mm (.87")

  • Page 135: Tramp Release Cylinder And Accumulator Removal

    Crusher does not have these holes in be suspected. the drive ring contact Metso Product Due to the size and weight of the accumulator it is Support Department for instructions on how necessary to remove and install the tramp release and where to add the holes.
  • Page 136 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 2. Lock out and tag all electrical power 3. Disconnect the release circuit hoses on both supplied to the power unit and Crusher and sides of the tramp release cylinder. If the depressurize the clamping and tramp release release cylinder to be removed has the hose circuits by opening the clamping cylinder...

  • Page 137: Tramp Release Cylinder And Accumulator Installation

    Metso Product Support Department for the drive ring. instructions on how and where to add the 7.
  • Page 138 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 4. Thread an M20 eyebolt into the end of the 8. With the threaded end of the cylinder rod cylinder rod. The eyebolt must be turned above the top of the adjustment ring, first down completely so that the shoulder of the coat the bearing cone with “never seize”...

  • Page 139: Clearing Jack Removal

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3.4.6 Clearing Jack Removal 3. Attach a sling around the cylinder, and attach the free end of the sling to a suitable A leaking clearing jack is a condition which should lifting device.

  • Page 140: Clearing Jack Installation

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3.4.7 Clearing Jack Installation The accumulator gas pressure should be checked every 200 hours (1 month). If the accumulator gas Install a new or repaired cylinder, as follows: pressure is not at its normal pre-charge level, 1.
  • Page 141 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 1. Lock out and tag all electrical power supplied to the power unit and Crusher and depressurize the clamping and tramp release circuits by opening the clamping cylinder and tramp release cylinder needle valves located on the side of the hydraulic power unit at the hose connection area.
  • Page 142 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY The gauging assembly consists of an 10. Due to the physical size and weight of the adapter, bleeder valve, tank valve and accumulator it is necessary to remove the pressure gauge which are attached as one tramp release cylinder and accumulator as unit directly to the gas valve stem on the...

  • Page 143: Accumulator Bladder Replacement

    MP1000, three on the MP800, located on the outside diameter of 3. Clean frame bore, inspect and measure the adjustment ring. Refer to Figure 3-7 and diameters. Convey this information to Metso Figure 3-20. Product Support Department for possible rework requirements.
  • Page 144 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3. Place the adjustment ring assembly onto the main frame so that the clamping cylinder MP800 MP1000 hose connection is located opposite the 56 C 50 C countershaft box.
  • Page 145 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 1. Create a limited amount of ring bounce by adjusting the Crusher setting while monitoring the analog output readings from the MCM Modules. 2. When ring bounce is detected, select the highest analog value and use that as your alarm setpoint.

  • Page 146: Adjustment Ring Disassembly

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY n0540 Callout Description Vibration Sensor Vibration Transmitter Proximity Sensor Figure 3-22 Vibration Sensor Locations (MP800 Shown) 3.4.12 Adjustment Ring Disassembly 2. If the clamping ring is to be removed from the adjustment ring, then first remove the The various sealing and clamping components that dust shell from the adjustment ring by...
  • Page 147 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 7. If the adjustment ring is to be taken off the frame, all the tramp release cylinders have to be removed from the Crusher as described under Tramp Release Cylinder and Accumulator Removal in this section.

  • Page 148: Clamping Cylinder Removal

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 3.4.13 Clamping Cylinder Removal Remove a faulty clamping cylinder as follows: 1. Remove the clamping ring as described in steps 1 through 5 under Adjustment Ring Disassembly in this section. 2.

  • Page 149: Clamping Cylinder Disassembly And Repair

    SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY 5. Remove the mounting bolts from the top of 3. Install the tee or elbow and hoses to the top the clamping cylinder refer to Figure 3-25. of the cylinder using Loctite 545 thread sealant on the fitting connections.
  • Page 150 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY bolts and spacers on the MP1000 and six on the MP800. Refer to Figure 3-23. 7. Connect the elbow to the hose that runs from the top of the adjustment ring and up through the clamp ring.
  • Page 151 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY MP800 MP1000 Callout Description Callout Description Centerline of countershaft Hose Ø 50 mm (2") hole in clamp ring Adjustment ring Clamping cylinders Hose guard Figure 3-26 Clamping Cylinder Hose Connections 3-33 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 152 SECTION 3 - M. FRAME, ADJ. RING, TRAMP REL. & CLRNG JACK ASSY This Page Left Intentionally Blank. 3-34 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 153 Section 4 Countershaft, Countershaft Box & Sheave Assemblies Description ............. . Assembly Instructions .
  • Page 154 Callout Description Countershaft Countershaft box Countershaft and Countershaft Box...

  • Page 155: Description

    Countershaft, Ctrshaft Box & Sheave Assemblies ECTION 4.1 Description Crusher that the proper end float is maintained. The countershaft must be free to This section covers the countershaft box, move in and out. To check the end float do countershaft and crusher sheave assemblies. Power the following: is transmitted from the initial power source to the countershaft through a V-belt or a direct drive.
  • Page 156 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES Callout Description Callout Description Inner countershaft bushing Sheave bushing Countershaft Clamp screw Outer countershaft bushing Tight Oil flinger No clearance (tight) Measure end float here. Sheave key 1.5 mm (0.060") to 0.8 mm (0.030") Set collar (direct drive) Figure 4-1 End Float —...
  • Page 157 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES Callout Description Callout Description Pinion Sheave assembly Wear ring Countershaft O-ring Countershaft box Box guard Oil flinger Box shield Countershaft box cover Bushing Countershaft bushing RTD Figure 4-2 Countershaft, Countershaft Box and Sheave Assembly (MP800) On the MP1000 only apply a sealant, 6.
  • Page 158 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES Callout Description Callout Description Pinion Countershaft Wear ring Countershaft box O-ring Oil flinger Box guards Flinger housing Box shield Rectangular seal Bushing Countershaft bushing RTD Sheave assembly Figure 4-3 Countershaft, Countershaft Box and Sheave Assembly (MP1000) MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 159 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 9.5 mm MP800 MP1000 Callout Description Callout Description Main frame Frame ring Coat this surface with a thin film of grease Rectangular seal Coat this surface with Silastic before O-ring mounting seal onto countershaft box Countershaft box Coat this surface of seal with Silastic just prior to installing box into frame...
  • Page 160 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES Callout Description Callout Description Lifting slings Countershaft box centering lug Sheave bushing (or set collar, Frame support guide direct drive) Figure 4-5 Installing Countershaft Box Assembly 7. Lower the pinion end of the countershaft box, again making sure the countershaft box centering lug rests on the main frame guide support.

  • Page 161: Crusher Sheave Installation (V-Belt Drive)

    SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 11. Remove the two pull-in capscrews and install six M42 x 140 mm LG capscrews for the MP1000 or six M36 x 120 mm LG 50 mm capscrews for the MP800 along with their lockwashers.

  • Page 162: Crusher Sheave Removal

    SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES Table 4-1 Crusher Sheave Take-up Bolt Torque Crusher No. of Sheave Take-Up Bolt Size Bolts Torque MP1000 1017 Nm (750 ft.lbs) MP800 813 Nm (600 ft.lbs) 4.2.3 Crusher Sheave Removal To remove the crusher sheave and proceed as follows (refer to Figure 4-8): 1.
  • Page 163 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 2. Remove all oil and blower piping that would interfere with the removal of the box. Plug and cap all open ports. 3. Remove the crusher sheave at this point as described under Crusher Sheave Removal earlier in this section.

  • Page 164: Pinion Replacement

    SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 13. Remove the lifting sling from around the it is recommended that gear and pinion be replaced pinion end of the countershaft box then at the same time. If a new pinion is run with a worn attach the sling just removed around the box gear, the root clearance must be checked as on the outside of the Crusher as close to the...

  • Page 165: Countershaft Bushing Removal

    SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES Callout Description “C” Clamp Pinion n0518 Countershaft Callout Description MP1000 — 5 mm (0.197") Countershaft MP800 — 10 mm (0.393") Pinion Figure 4-11 Installing Pinion Wood blocking 4.3.3 Countershaft Bushing Removal Figure 4-10 Pinion Removal When a bushing becomes worn and replacement is necessary, the bushing may be loose in the box.
  • Page 166 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 2. Construct a steel centering plate as shown in Figure 4-12. 3. Slide the narrow portion of the plate through the bushing until the plate is behind the bushing as shown. Turn the centering plate 90°...

  • Page 167: Inspection Prior To Bushing Installation

    SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 4.3.4 Inspection Prior to Bushing remachined to meet these limits. An excessive Installation interference fit can cause the bushing to collapse or the bushing bore to become smaller thereby As a precautionary measure prior to installing a reducing the clearance between countershaft and new bushing, check the diameter of the bore in the bushing.

  • Page 168: Countershaft Bushing Installation

    SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES Callout Description Callout Description Inner countershaft bushing Threaded rod Centering plate Flat bar Countershaft box Blocking Outer countershaft bushing Figure 4-14 Countershaft Bushing Removal by Jacking If the bore of the bushing has become smaller from location of the bushing oil groove in relation excessive pressure when installing into an to the countershaft box as follows:...

  • Page 169: Countershaft Box Assembly

    SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 2. Insert a feeler gauge of proper thickness, as NOTICE specified in Figure 4-17, between the pinion and countershaft bushing. Wrap the outside of the bushing in a few 3. To hold the countershaft stationary, place a layers of fiberglass insulation to prevent the large “C”...
  • Page 170 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 5. MP1000 6. MP1000 If the oil flinger is not being replaced follow Apply a light coat of grease to one side of instructions in 5(a) before proceeding to step the flinger housing gasket. Stick the greased 6.
  • Page 171 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES Callout Description Callout Description Countershaft box bushing Flinger key Countershaft box Countershaft Oil flinger Piston ring Figure 4-16 MP1000 Flinger Key Callout Description Callout Description 0.8 mm (0.030") to 1.5 mm Countershaft (0.060") end float Outer countershaft bushing...

  • Page 172: Oil Leakage From Drive End Of Countershaft Box

    SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES 4.3.7 Oil Leakage from Drive End of 3. Remove the front O-ring, wear ring and rectangular seal from the countershaft box. Countershaft Box Remove all the Silastic that was used to hold MP1000 the rectangular seal in place.
  • Page 173 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES MP1000 MP800 Callout Description Callout Description O-ring Countershaft box Wear ring No space on worn area Main frame Worn wear ring Frame ring New wear ring Rectangular seal Excessively worn wear ring Clearance Figure 4-18 Countershaft Box Seals 4-19...
  • Page 174 SECTION 4 - COUNTERSHAFT, CTRSHAFT BOX & SHEAVE ASSEMBLIES This Page Left Intentionally Blank. 4-20 MP SERIES CONE CRUSHER TECHNICAL REFERENCE MANUAL...
  • Page 175 Section 5 Eccentric Assembly Description ............. . Assembly Instructions .
  • Page 176 Callout Description Eccentric Counterweight Upper thrust bearing Eccentric bushing Gear T & U seals Counterweight guard Eccentric and Counterweight Assemblies...
  • Page 177 Eccentric Assembly ECTION 5.1 Description supported by a set of thrust bearings; the upper thrust bearing is bolted to the bottom of the This section covers the eccentric assembly eccentric and the stationary lower thrust bearing is including the eccentric, eccentric bushing, gear and bolted to the main frame.
  • Page 178 SECTION 5 - ECCENTRIC ASSEMBLY Molded, nonmetallic stationary T-seals and U-seals, until the upper thrust bearing is resting on cemented into grooves around the top and bottom the lower thrust bearing. Also position one of the counterweight provide a labyrinth type seal of the large cored kidney shaped slots in the that prevents oil leakage and protects the gear, counterweight directly over the pinion.
  • Page 179 SECTION 5 - ECCENTRIC ASSEMBLY matches the pitch diameter of the pinion. A tool is To check or adjust backlash or root clearance, available for this method and Tables 5-1A, B proceed as follows: (MP800) and 5-2A, B (MP1000) list the backlash 5.2.2.1 For Spiral Bevel Gear Sets requirements based on the type of gear set provided with your Crusher.
  • Page 180 Table 5-3A (MP800) or Table 5-2C shims placed beneath the lower thrust (MP1000), the eccentric assembly is to be bearing when the Crusher left Metso removed and metal shims of the proper Minerals are of the required thickness to thickness are to be added under the lower provide proper backlash and root clearance.

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